A blank to be inserted in a package, a package and a method for providing a package

Abstract

The present disclosure relates to a blank to be inserted in a package for providing thermal insulation and / or shock-absorbing properties. The blank comprises a first set of panels being foldably interconnected and a second set of panels being foldably connected to preferably one of the panels, of the first set of panels. At least two of the panels of the first set of panels are foldably connected along a groove having a depth and a width. The depth of the groove is greater than the width such that, as a first panel is folded relative to a second panel a groove edge portion of the first major surface on the first panel extends into the groove and abuts a side wall of the groove formed on the second panel. The present disclosure also relates to a package having insulation and / or shock-absorbing properties and a method for providing a package.

Description

[0001] A BLANK TO BE INSERTED IN A PACKAGE, A PACKAGE AND A METHOD FOR PROVIDING A PACKAGE

[0002] Field of invention

[0003] The invention relates to a blank to be inserted in a package for providing thermal insulation and / or shock-absorbing properties to the package. The invention also relates to a package having thermal insulation and / or shock-absorbing properties. The invention also relates to a method for providing a package with thermal insulation and / or shock-absorbing properties.

[0004] Technical backoround

[0005] Insulated packaging is a type of packaging that is designed to protect products from temperature fluctuations during transportation and storage. Insulated packaging can be made from a variety of materials, including foam, polystyrene, and cardboard. Insulated packaging is typically used for perishable items such as food, pharmaceuticals, and biological samples.

[0006] There are several factors to consider when designing an insulated package. The first is that the insulation should provide good temperature insulating properties while preferably also providing shock-absorbing protection to the products. It is known to accomplish such insulation using inserts of insulating material positioned inside packages e.g., made from paperboard. The insulation should typically be designed such that it makes efficient use of material, is easy to manufacture, is easy to transport to the point of use, and is easy to prepare for use.

[0007] Furthermore, the insulation should have a good fit with the package in which it is installed. Proper positioning of the insulation is typically an important factor when it comes to ensuring that the insulation is effective as such, and also when it comes to securing is effectiveness over time since proper positioning typically has a positive impact on securing that the insulation does not become damaged or dislodged over time. Proper positioning typically involves proper positioning of the different pieces of insulation in relation to each other and in relation to a package in which they are positioned. Proper positioning typically entails that there is a good fit between the different pieces of insulation and the package. If the insulation has a poor fit both the insulating properties and the shock-absorbing properties of the package will typically be reduced.

[0008] Thus, there is still a need for a blank adequately addressing at least some of the design criteria mentioned above.

[0009] Summary of invention

[0010] It is an object of the invention to provide a solution that addresses at least some of the design criteria described above, namely, to provide thermal insulation and / or shock absorbing properties to a package. Preferably, this should be accomplished in a manner making efficient use of material, being easy to manufacture, being easy to transport to the point of use, and being easy to prepare for use. This has in accordance with a first aspect been accomplished by a blank to be inserted in a package for providing thermal insulation and / or shock-absorbing properties to the package. The blank comprising, as seen in a flat-laid state of the blank ; a first set of panels being foldably interconnected and being arranged one after the other in a longitudinal direction, and a second set of panels being foldably connected to one longitudinally extending edge, or a respective one of two longitudinally extending edges, of at least one of the panels, preferably one of the panels, of the first set of panels, wherein at least two of the panels of the first set of panels are foldably connected along a groove, the groove being formed in a first major surface of the blank and having a depth and a width, wherein the depth of the groove is greater than the width of the respective groove such that, as a first panel of said at least two of the panels of the first set of panels is folded relative to a second panel of said at least two of the panels of the first set of panels, a groove edge portion of the first major surface on the first panel extends into the groove and abuts a side wall of the groove formed on the second panel.

[0011] As the depth of the groove is greater than the width of the respective groove, the groove edge portion of the first major surface on the first panel abuts the side wall such that the first panel is kept in the groove. In other words, the first panel is aided to keep its position with its groove edge portion extending into the groove. When the width is shorter than the depth, the bottom of the groove will be stretched and will thereby provide a pulling force that keeps the groove edge portion of the first panel in position inside the groove. The blank will therefore be aided in keeping the shape when the blank is in the package. The risk of the blank unfolding is reduced. It is advantageous that the blank keeps its shape as it reduces the risk that the protection of goods and that the temperature control of the package is reduced during transportation. If the blank losses its shape inside the package there may occur openings between the panels of the blank, which reduces the thermal insulation capabilities of the blank. Thus, the blank is advantageous as it facilitates providing thermal insulation to the package and also facilitates providing protection of goods if the blank is provided with shock-absorbing properties. It may in this context be noted that shockabsorbing properties refers to mechanical shocks, such as internal or external impacts. An external impact may e.g., be caused by an external force such as a fork of a forklift hitting the package. An internal impact may e.g., be due to heavy goods moving inside and relative to the package when a truck drives over a bump or the like.

[0012] Furthermore, when the depth is greater than the width there will be a tight fit in the connection points between the first panel and the second panel of the folded blank. The first panel and the second panel will be pulled together at the inside of the corners formed when folding the blank. This will result in an increased tightness at the inside of the corners which in turn typically has a positive impact on the thermal insulation of the package as it restricts air entering / leaving the storage area of the package.

[0013] When the blank is folded, the groove edge portion of the first major surface on the first panel extends into the groove and abuts a side wall of the groove formed on the second panel. In other words, the first panel is folded into the groove such that a part of the first major surface is located inside the groove such that there is an overlap of the first panel and the second panel. This results in that the second panel meets the first panel partly up on to the first major surface.

[0014] It may in this context also be noted that the first set of panels and the second set of panels allows for a plurality of different configurations of the blank. The blank may for example have a T-shape, an L-shape, or a crossshape. This is advantageous as it provides a flexibility to the blank during the production which may allow for an efficient use of material as well as resulting in that the blank is easy to manufacture.

[0015] The first set of panels may e.g., comprise a first main panel, a second main panel, a third main panel and a fourth main panel. The second set of panels may e.g., comprise a first end panel and a second end panel.

[0016] As an example, if the blank is T-shaped, the two end panels may be oppositely arranged at and foldably connected to a respective one of two oppositely arranged longitudinally extending side portions of the first main panel, the second main panel may be foldably connected to a transversally extending side portion of the first main panel, the third main panel may be foldably connected to a transversally extending side portion of the second main panel, and the fourth main panel may be foldably connected to a transversally extending side portion of the third main panel.

[0017] As an example, if the blank is L-shaped, the second main panel may be foldably connected to a transversally extending side portion of the first main panel, the third main panel may be foldably connected to a transversally extending side portion of the second main panel, the fourth main panel may be foldably connected to a transversally extending side portion of the third main panel, the first end panel may be arranged at and foldably connected to one longitudinally extending side portion of the first main panel, and the second end panel may be arranged at and foldably connected to one longitudinally extending side portion of the first end panel such that the second end panel and the first main panel are positioned on opposite sides of the first end panel.

[0018] As an example, if the blank is cross-shaped, the second main panel may be foldably connected to a transversally extending side portion of the first main panel, the two end panels may be oppositely arranged at and foldably connected to a respective one of two oppositely arranged longitudinally extending side portions of the second main panel, the third main panel may be foldably connected to a transversally extending side portion of the second main panel, and the fourth main panel may be foldably connected to a transversally extending side portion of the third main panel.

[0019] With foldably connected is herein meant that the two panels are connected to each other and that the connection is preferably provided with a fold line between the two panels such that the blank is weakened at this line in the sense of facilitating a folding manoeuvre when folding. The fold lines may e.g., be a so-called crease line, a perforation, or a partial cut-line, or a groove depending upon the kind of material from which the blank is cut. In the preferred embodiments of the different configurations, all the fold lines are designed as a groove having a depth being greater than the width of the respective groove in a manner introduced above and more preferably of a kind discussed in more detail in the following.

[0020] The blank may be made of a material that is resiliently stretchable by hand such that material which is located at the bottom of the respective groove and which interconnects said at least two of the panels of the first set of panels is stretchable, thereby aiding the groove edge portion of the first panel to be positioned in the groove.

[0021] The resiliently stretchable material allows the groove edge portion of the first panel to be positioned deep into the groove, past the nominal point of contact defined by the non-stretched geometry. The first panel will be further secured against the second panel, thereby the first panel will have further support from the side wall of the groove. Therefore, the function keeping the first panel and the second panel together will be further increased compared to when the non-stretched geometry is used.

[0022] The resiliently stretchable material may also allow the user to easily fold and positioning the first panel into the groove. This may further increase the user-friendliness of the blank.

[0023] The blank may be made of a material that is resiliently compressible by hand such that the groove edge portion of the first major surface on the first panel is compressible, and resilient such that it abuts the wall of the groove with a force, thereby aiding the groove edge portion of the first panel to be positioned in the groove.

[0024] A resiliently compressible material provides similar advantages as a resiliently stretchable material. Namely that the resiliently compressible material allows the groove edge portion of the first panel to be positioned deep into the groove, past the nominal point of contact defined by the non- compressible geometry. The first panel will be further secured against the second panel, thereby the first panel will have further support from the side wall of the groove. Therefore, the function keeping the first panel and the second panel together will be further increased compared to when the noncompressed geometry is used.

[0025] A resiliently compressible material will also allow the user to easily fold and positioning the first panel into the groove. This may further increase the user-friendliness of the blank.

[0026] When the portion of the first major surface being closest to the groove is folded into the groove there will be a compression of that portion which will also transfer into a in plane stretching of the material. Thus, a suitable material may be identified using an indentation test in accordance with standard ISO 2439:2009. With a test probe diameter of 200mm and at an indentation depth of 25%, the hardness given as a force [N] should preferably be about 7-25N, more preferably about 10-20N. With a test probe diameter of 200mm and at an indentation depth of 40%, the hardness given as a force [N] should preferably be about 50-125N, more preferably about 70-100N. Preferably, at least one of the above criteria is fulfilled and more preferably both criteria are fulfilled; preferably according to the wide intervals, more preferably according to one wide interval and one narrow interval, and most preferably according to the two narrow intervals. If the hardness value is too small, the material will not provide the desired effect of the material remaining in the folded position. It the hardness value is too high, it starts to become difficult to fold the material such that the groove edge portion of the first major surface extends into the groove, such that one starts to be forced to use tighter tolerances. Moreover, if the hardness value is too high there is also a risk that the desired properties, especially concerning thermal insulation, starts to deteriorate, since materials with higher hardness values tend to be more dense than desired.

[0027] The resilience of the material is preferably such that there is at least 50% reflexion after release of elongations being less than 10%. This resilience of 50% reflexion is preferably at least true after being released after an elongation of less than and up to 10% for less than 5 minutes. This resilience of 50% is preferably also true after being released after an elongation of less than and up to 10% for up to 24 hours. The elongation test is e.g., performed by uniformly stretching e.g., a 10 cm by 10 cm test piece in a stretching direction extending along two of the sides and orthogonally to the other two sides, and the test piece may e.g., have a thickness of between 15- 60 mm, such as e.g., 30mm, to provide sufficient reliability and repeatability by e.g., avoiding any practical impacts due to boundary conditions which might occur if testing was to be performed on too small or thin test pieces. Long-term resilience may be determined using a compression test according to ISO standard 1856:2018. After a compression to 50% during 72h at a temperature of 23°C, the remaining compression set should preferably be less than 50, more preferably less than 30%. It may in this context be noted that the hardness values and / or the resilience values discussed above are relevant to any fibrous material as such, but that they are especially suitable when considered in combination with the density and / or the length-weighted average fibre length discussed below.

[0028] The groove may have a rectangular shape.

[0029] This is advantageous as it is a shape that typically is easy to manufacture. A rectangular shape is also a shape that is easy to control during manufacturing and a shape with foreseeable behaviour during folding which facilitates securing such that the depth of the groove in practice is greater than the width. A rectangular shape may also be provided with sharp corners and straight walls which typically improves the functionality of the first panel being aided to stay in the groove.

[0030] A generally rectangular groove may have an undercut such that an overhang is provided. The undercut may be provided at the side wall of the groove such that, when folded, the first panel will be further aided to keep its position in the groove with the groove edge portion of the first major surface on the first panel abutting the side wall of the groove. The first panel will be further aided to keep its position as the overhang of the side wall will restrict movement of the first panel.

[0031] All of the panels of the first set of panels may be foldably connected to neighbouring panels of the first set of panels along a groove, wherein, preferably, each such groove has a depth being greater than a width thereof.

[0032] It is advantageous that all of the panels of the first set of panels are foldably connected to neighbouring panels along a groove as all of the connection points between the first set of panels will have the advantages of such a groove. This will typically further improve the thermal insulation and the protection of the package. It may in this context be noted that each of these grooves connecting the panels of the first set of panels may, but need not, be of a kind involving all the features discussed above. The panel or those panels of the second set of panels that is / are directly connected to a panel of the first set of panels may be foldably connected thereto along a groove, wherein, preferably, each such groove has a depth being greater than a width thereof.

[0033] It is advantageous that the panels of the second set of panels that are directly connected to a panel of the first set of panels is foldably connected along a groove as all of the connection points between the first set of panels and the panels of the second set of panels will have the advantages of such a groove. This will typically further improve the thermal insulation and the protection of the package. It may in this context be noted that each of these grooves connecting the panels of the second set to one or more of the panels of the first set of panels may, but need not, be of a kind involving all the features discussed above.

[0034] All of the panels of the second set of panels may be foldably connected to a panel of the first set of panels or to a panel of the second set of panels along a groove, wherein, preferably, each such groove has a depth being greater than a width thereof.

[0035] It is advantageous that all of the panels of the second set of panels are foldably connected to a panel of the first set of panels or to a panel of the second set of panels along a groove as all of the connection points between the first set of panels and the panels of the second set of panels will have the advantages of such a groove. This will typically further improve the thermal insulation and the protection of the package. It may in this context e noted that each of these grooves connecting panels of the second set of panels to the other panels may, but need not, be of a kind involving all the features discussed above.

[0036] The blank may have a material thickness of 15-60 mm. With such material thickness, the blank may be used in most type of packages suitable for delivering for example food products, pharmaceuticals, and other fragile, and / or temperature sensitive products. The depth of the groove may be from 50% to 80% of the material thickness, and preferably from 60% to 80% of the material thickness.

[0037] When the depth of the groove is between 50-80% of the material thickness, a balance between cutting the groove deep enough to secure abutment of the groove edge portion of the first major surface on the first panel against the side wall of the groove while still having enough thickness at the material of the groove to reduce the risk that the material in the groove breaks may be achieved. When the groove is comparably deep, a comparably large part of the first major surface of the first panel will extend into the groove and therefore a comparably large portion of the first major surface will be the groove edge portion and abut the side wall of the groove, which improves the stability of the folded blank. When the groove is comparably shallow, the durability of the material interconnecting the panels at the fold may be increased.

[0038] The depth of the groove may be from 105% to 140% of the width, and preferably from 105% to 125% of the width.

[0039] When the depth of the groove increases compared to the width, a comparably large portion of the first major surface on the first panel may extend into the groove when the blank is folded. When the overlap is comparably large the stability of the fold may increase as a comparably large portion act as the groove edge portion and abuts the side wall of the groove. However, if the depth is to deep there may be an ineffective use of material. Therefore, it may be advantageous to limit the depth of the groove compared to the width of the groove.

[0040] In short, the material of the blank may be a fibrous material comprising natural fibres having a length-weighted average fibre length from about 0.8 mm up to about 5 mm and may be provided at a concentration of at least 70 % by weight of the material, wherein the fibrous material preferably may be an air-laid material. The material of the blank may have an average density of 10 to 60 kg / m3. The material is preferably an air-laid material. The air-laid material may comprise natural fibres at a concentration of at least 70 % by weight of the air-laid material and a polymer binder, e.g., a thermoplastic polymer binder, at a concentration selected within an interval of from 2.5 up to 30 % by weight of the air-laid material. The air-laid material may also comprise one or more additives. The air-laid material is formed by a process known as air-laying, in which cellulose and / or lignocellulose fibres and polymer binders are mixed with air to form a porous fibre mixture deposited onto a support and consolidated or bonded by heating. This air-laid material, sometimes also referred to as dry-laid material, is characterized by being porous, having the character of an open cell foam and being produced in a so-called dry forming method, i.e., generally without addition of water. The air-laying process may e.g., be of a kind described in U.S. patent no. 3,575,749.

[0041] In an embodiment, the natural fibres are wood fibres. In a particular embodiment, the natural fibres are cellulose and / or lignocellulose fibres. Hence, in an embodiment, the natural fibres contain cellulose, such as in the form of cellulose and / or lignocellulose, i.e., a mixture of cellulose and lignin. The natural fibres may also contain lignin, such as in the form of lignocellulose. The natural fibres may additionally contain hemicellulose. In a particular embodiment, the natural fibres are cellulose and / or lignocellulose pulp fibres produced by chemical, mechanical and / or chemo-mechanical pulping of softwood and / or hardwood. For instance, the cellulose and / or lignocellulose pulp fibres are in a form selected from the group consisting of sulfate pulp, sulfite pulp, thermomechanical pulp, high temperature thermomechanical pulp, mechanical fibre intended for medium density fibreboard, chemo-thermomechanical pulp, high temperature chemo- thermomechanical pulp, and a combination thereof.

[0042] The natural fibres can also be produced by other pulping methods and / or from other cellulosic or lignocellulosic raw materials, such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, straw or rice husk. The air-laid material may comprise the natural fibres in a concentration of at least 70 % by weight of the air-laid material. In a preferred embodiment, the air-laid material comprises the natural fibres in a concentration of at least 72.5 %, more preferably at least 75 %, such as at least 77.5 %, at least 80 %, at least 82.5 %, at least 85 % by weight of the air-laid material. In some applications, even higher concentrations of the natural fibres may be used, such as at least 87.5 %, or at least 90 %, at least 92.5 %, at least 95 % or at least 96 % by weight of the air-laid material.

[0043] The thermoplastic polymer binder is included in the air-laid material as binder that binds the air-laid material together and preserves its form and structure during use, handling and storage. The thermoplastic polymer binder may also assist in building up the foam-like structure of the air-laid material. The thermoplastic polymer binder is intermingled with the natural fibres during the air-laying process forming a fibre mixture. The thermoplastic polymer binder may be added in the form of a powder, but are more often in the form of fibres that are intermingled with the natural fibres in the air-laying process. Alternatively, or in addition, the thermoplastic polymer binder may be added as solution, emulsion or dispersion into and onto the air-laid material during the air-laying process. This latter technique is most suitable for thin air-laid materials.

[0044] In a particular embodiment, the thermoplastic polymer binder is selected from the group consisting of a thermoplastic polymer powder, thermoplastic polymer fibres and a combination thereof

[0045] In an embodiment, the thermoplastic polymer binder has a softening point not exceeding a degradation temperature of the natural fibres.

[0046] In an embodiment, the thermoplastic polymer binder is or comprises thermoplastic polymer fibres cut at a fixed length, which are typically referred to as staple fibres. It is generally preferred for the mixing in the air-laying process and, thereby, for the properties of the formed air-laid material if the length of the thermoplastic polymer fibres is of the same order of magnitude as the length of the natural fibres. Length of the thermoplastic polymer fibres and the natural fibres as referred to herein is length weighted average fibre length. Length weighted average fibre length is calculated as the sum of individual fibre lengths squared divided by the sum of the individual fibre lengths.

[0047] In an embodiment, the thermoplastic polymer binder is or comprises thermoplastic polymer fibres having a length weighted average fibre length that is selected within an interval of from 75 % up to 300 %, preferably from 80 % up to 250 %, and more preferably from 90 % up to 220 %, such as from 95 % up to 200 % of a length weighted average fibre length of the natural fibres. In a particular embodiment, the thermoplastic polymer fibres have a length weighted average fibre length within an interval of from 1 up to 10 mm, preferably within an interval of from 2 up to 8 mm and more preferably within an interval of from 2 up to 6 mm.

[0048] The length weighted average fibre length of the natural fibres is dependent on the source of the natural fibres, such as tree species they are derived from, and the pulping process. A typical interval of length weighted average fibre length of wood pulp fibres is from about 0.8 mm up to about 5 mm.

[0049] In an embodiment, the thermoplastic polymer binder is or comprises mono-component and / or bi-component thermoplastic polymer fibres. Bicomponent thermoplastic polymer fibres, also known as bico fibres, comprise a core and sheath structure, where the core is made from a first polymer, copolymer and / or polymer mixture and the sheath is made from a second, different polymer, copolymer and / or polymer mixture.

[0050] In an embodiment, the thermoplastic polymer binder is or comprises, such as consists of, mono-component thermoplastic polymer fibres made of a material selected from the group consisting of polyethylene, ethylene acrylic acid copolymer, ethylene-vinyl acetate, polypropylene, polystyrene, polybutylene adipate terephthalate, polybutylene succinate, polylactic acid, polyethylene terephthalate, polycaprolactone and copolymers and / or mixtures thereof. In another embodiment, the thermoplastic polymer binder is or comprises, such as consists of, bi-component thermoplastic polymer fibres having a core and / or sheath made of a material or materials selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL and copolymers and / or mixtures thereof. In a further embodiment, the thermoplastic polymer binder is or comprises, such as consists of, a combination or mixture of mono-component thermoplastic polymer fibres made of a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL and copolymers and / or mixtures thereof and bi-component thermoplastic polymer fibres having a core and / or sheath made of a material or materials selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL and copolymers and / or mixtures thereof.

[0051] The thermoplastic polymer binder may be made of a single type of thermoplastic polymer fibres, i.e., made of a same material in the case of mono-component thermoplastic polymer fibres or made of the same material or materials in the case of bi-component thermoplastic polymer fibres. However, it is also possible to use a thermoplastic polymer binder made of multiple different mono-component thermoplastic polymer fibres made of different materials and / or multiple different bi-component thermoplastic polymer fibres made of different materials.

[0052] In an embodiment, the thermoplastic polymer binder is or comprises a thermoplastic polymer powder made of a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL and copolymers and / or mixtures thereof.

[0053] Particular examples of material for the thermoplastic polymer binder that could be used according to the present embodiments include PBAT, PBS, PLA, PCL, and copolymers and / or mixtures thereof. In such a case, the thermoplastic polymer binder made of these materials is compostable under industrial conditions.

[0054] Other examples of material for the thermoplastic polymer binder, which are water soluble, are mono-component and / or bi-component thermoplastic polymer fibres made of a material selected from the group consisting of polyvinyl alcohol, polyethylene glycol, poly , polyvinyl ether, polyvinylpyrrolidone, polyacrylic acid, polymethacrylic acid and copolymers and / or mixtures thereof.

[0055] In an embodiment, the thermoplastic polymer binder is or comprises, such as consists of, mono-component thermoplastic polymer fibres made of a material selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMAA and copolymers and / or mixtures thereof. In another embodiment, the thermoplastic polymer binder is or comprises, such as consists of, bicomponent thermoplastic polymer fibres having a sheath or a sheath and core made of a material or materials selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMMA and copolymers and / or mixtures thereof. In a particular embodiment, at least the sheath of the bi-component thermoplastic polymer fibres is made of a material selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMAA and copolymers and / or mixtures thereof. In such a particular embodiment, also the material of the core of the bi-component thermoplastic polymer fibres could be selected from this group. However, if the core of the bi-component thermoplastic polymer fibres does not soften to become tacky and attach to the natural fibres in the hot pressing the core may actually be made of a material that are not necessarily water soluble at the repulping temperature. This means that the core could be made of the previously mentioned thermoplastic polymer materials. Hence, in this particular embodiment, the bi-component thermoplastic polymer fibres comprise a core component made of a material selected from the group consisting of polyethylene PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL and copolymers and / or mixtures thereof and a sheath component made of a material selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMAA and copolymers and / or mixtures thereof. In a further embodiment, the thermoplastic polymer binder is or comprises, such as consists of, a combination of mono-component thermoplastic polymer fibres made of a material selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMAA and copolymers and / or mixtures thereof and bi-component thermoplastic polymer fibres having a core and / or sheath made of a material or materials selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMAA and copolymers and / or mixtures thereof.

[0056] In an embodiment, the thermoplastic polymer binder is or comprises a thermoplastic polymer powder made of a material selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMAA and copolymers and / or mixtures thereof.

[0057] In an embodiment, the air-laid material comprises the thermoplastic polymer binder at a concentration selected within an interval of from 10 up to 30 %, such as from 15 up to 30 % by weight of the air-laid blank 10. In a particular embodiment, the air-laid material comprises more than 15 % but no more than 30 % by weight of the thermoplastic polymer binder. For instance, the air-laid material comprises the thermoplastic polymer binder at a concentration selected within an interval of from 15 or 17.5 up to 30 % by weight of the air-laid blank 10. In a particular embodiment, the air-laid material comprises the thermoplastic polymer binder at a concentration selected within an interval of from 15 or 17.5 up to 25 %, such as from 20 up to 25 % by weight of the air-laid material.

[0058] In some embodiments, the air-laid material comprises the thermoplastic polymer binder at a concentration selected within an interval of from 2.5 up to 15 % by weight of the air-laid material, preferably within an interval of from 4 up to 15 % by weight or the air-laid blank 10, or within an interval of from 7.5 up to 15 % by weight of the air-laid material, and more preferably within an interval of from 10 up to 15 % by weight of the air-laid material. These embodiments are, in particular, suitable for usage with thermoplastic polymer binders that are water soluble, e.g., for usage with thermoplastic polymer fibres made from a material or materials selected from the group consisting of PVA, PEG, PEOX, PVE, PVP, PAA, PMAA and copolymers and / or mixtures thereof. The average density of the air-laid material may preferably be selected within an interval of from 10 to 60 kg / m3. Preferably, the average density of the air-laid material is within an interval of from 15 to 60 kg / m3, and more preferably within an interval of from 15 to 50 kg / m3.

[0059] The air-laid material may have a thickness of at least 20 mm, preferably at least 30 mm and more preferably at least 40 mm.

[0060] According to a second aspect of the present disclosure there is provided a package having thermal insulation and / or shock-absorbing properties. The package comprises, a bottom wall, a plurality of side walls, and a blank according to the first aspect, wherein the blank is folded and inserted into the package with the first major surface of the blank facing towards an interior of the package.

[0061] According to a third aspect of the present disclosure there is provided a method for providing a package with thermal insulation and / or shockabsorbing properties. The method comprises folding a package blank into a partly closed package, folding a blank according to the first aspect, inserting the folded blank into the partly closed package with the first major surface of the blank facing towards an interior of the package.

[0062] The advantages of the various features have been discussed above with reference to the blank according to the first aspect and those advantages are equally applicable with reference to the above package according to the second aspect and to the method according to the third aspect. Also, the various variants and preferred embodiments discussed with reference to the blank are equally applicable to the above package according to the second aspect and to the method according to the third aspect.

[0063] The invention may also in short be referred to as relating to a blank to be inserted in a package for providing thermal insulation and / or shockabsorbing properties, the blank comprising a first set of panels being foldably interconnected and a second set of panels being foldably connected to preferably one of the panels, of the first set of panels. At least two of the panels of the first set of panels are foldably connected along a groove having a depth and a width. The depth of the groove is greater than the width such that, as a first panel is folded relative to a second panel a groove edge portion of the first major surface on the first panel extends into the groove and abuts a side wall of the groove formed on the second panel.

[0064] It may be noted that the use of first, second, third, fourth, fifth, etc. are mainly to be seen as labels facilitating reading and that it does not necessarily mean that there need to be all the intervening numbers of portions or panels present. However, to facilitate reading, we have consistently used the numbering first, second, third, fourth, etc., as labels, and in a sense based on an embodiment including all conceivable portions.

[0065] Further scope of applicability of the present disclosure will become apparent from the detailed description given below. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the disclosure, are given by way of illustration and that various changes and modifications within the scope of the disclosure will become apparent to those skilled in the art from this detailed description.

[0066] Hence, it is to be understood that the present disclosure is not limited only to the particular parts of the blank, the package, or the steps of the methods described, since the actual implementation of such blank, package, and method may vary, and further parts or steps may be provided.

[0067] Brief description of the drawings

[0068] The invention will by way of example be described in more detail with reference to the appended schematic drawings, which shows a presently preferred embodiment of the invention.

[0069] Fig. 1 A discloses a blank for forming an insert to a package.

[0070] Fig. 1 B discloses a side view of the blank.

[0071] Fig. 2A discloses a close-up view of when the first panel is folded into the groove against the second panel in a suitable package. Fig. 2B discloses a close-up view of when the first panel is folded into the groove against the second panel in a package where there is more space between the corner of the folded blank and the corner of the package compared to the situation in Fig. 2A.

[0072] Fig. 3 discloses a folded blank.

[0073] Fig. 4 discloses a package with the blank inserted.

[0074] Fig. 5 discloses a method for providing a package.

[0075] Detailed description of preferred embodiments

[0076] Fig. 1 shows a blank 1 . The blank 1 is configured to be folded and inserted into a package 200 as illustrated in Fig. 4. The blank 1 is designed to provide thermal insulation and shock-absorbing properties to the package 200 in which the blank 1 is inserted. The blank 1 is further designed to in itself aiding in maintaining its shape after the blank 1 is folded such that connection points of the panels may keep the panels in contact with each other even if the blank 1 has a poor fit with the package 200, or if the package 200 is moved during transportation. This will be further described with reference to the figures. It may also facilitate insertion of the folded blank 1 into a package 200.

[0077] Turning to Fig. 1 A and Fig. 1 B a blank 1 for providing thermal insulation and / or shock-absorbing properties to the package 200 is illustrated. The blank 1 is illustrated in a flat-laid state. The blank 1 comprises a first set of panels 10, 11 , 12, 14 being foldably interconnected and being arranged one after the other in a longitudinal direction L, and a second set of panels 20, 21 being foldably connected to a respective one of two longitudinally extending edges 10a, 10b.

[0078] The first set of panels 10, 11 , 12, 14 and the second set of panels 20, 21 allows for a plurality of different configurations of the blank 1 . The blank 1 may for example have a T-shape, an L-shape, or a cross-shape. However, in the embodiment of Fig. 1 A and 1 B the blank 1 has a T-shape. The first set of panels 10, 1 1 , 12, 14 comprises a first main panel 10, a second main panel 11 , a third main panel 12 and a fourth main panel 14. The second set of panels 20, 21 comprises a first end panel 20 and a second end panel 21 The two end panels 20, 21 are oppositely arranged at and foldably connected to a respective one of two oppositely arranged longitudinally extending side portions 10a, 10b of the first main panel 10. The second main panel 11 is foldably connected to a transversally extending side portion 16 of the first main panel 10, the third main panel 12 is foldably connected to a transversally extending side portion 17 of the second main panel 11 , and the fourth main panel 14 is foldably connected to a transversally extending side portion 18 of the third main panel 12.

[0079] All of the panels 10, 11 , 12, 14 of the first set of panels 10, 11 , 12, 14 are foldably connected to neighbouring panels 10, 11 , 12, 14 of the first set of panels 10, 11 , 12, 14 along a respective groove 30. All of the panels 20, 21 of the second set of panels 20, 21 are foldably connected to the first main panel 10 along a respective groove 30. As is best shown in Fig. 2A, the respective groove 30 is designed such that, as a first panel, panel 10 in Fig. 2A, is folded relative to a second panel, panel 11 in Fig. 2A, a groove edge portion 32 of the first major surface 40 on the first panel 10 extends into the groove 30 and abuts a side wall 34 of the groove 30 formed on the second panel 11 .

[0080] The shape of the groove 30 is best viewed in Fig. 1 B where a side view of the blank 1 is illustrated. Each groove 30 has a rectangular shape having a depth d1 and a width w1 . The groove 30 is formed in the first major surface 40 of the blank 1 . The depth d1 of the groove 30 is greater than the width w1 for each respective groove 30.

[0081] In some embodiments the rectangular groove 30 may have an undercut such that an overhang is provided. The undercut may be provided at a side wall 34 of the groove 3O.The undercut may be advantageous when folding the blank 1 .

[0082] The blank 1 has a material thickness of 15-60 mm. With such material thickness the blank 1 may be used in most type of packages suitable for delivering for example food products, pharmaceuticals, and other fragile and / or temperature sensitive products.

[0083] The depth d1 of the groove 30 may be from 50% to 80% of the material thickness, and preferably from 60% to 80% of the material thickness.

[0084] When the depth d1 of the groove 30 is between 50-80% of the material thickness, a balance between cutting the groove 30 deep enough to secure the function when the blank 1 is folded while still having enough thickness at the material at a bottom 36 of the groove 30 to reduce the risk that the material at the bottom 36 of the groove 30 breaks may be achieved. When the groove 30 is deeper, a larger part of the first major surface 40 of the first panel will extend into the groove 30 and therefore a larger part will be the groove edge portion 32 which is in abutment against the side wall 34 of the groove 30 when the blank 1 is folded. When the groove 30 is shallower the durability at the fold may be increased.

[0085] The depth d1 of the groove 30 may be from 105% to 140% of the width w1 , and preferably from 105% to 125% of the width w1 . When the depth d1 of the groove 30 increases compared to the width w1 a larger portion of the first major surface 40 on the first panel may extend into the groove 30 when the blank 1 is folded. When the overlap is larger the stability of the fold may increase as a larger portion act as the groove edge portion 32 abuts the side wall 34 of the groove 30. However, if the depth d1 is to deep there may be an ineffective use of material. Therefore, it may be advantageous to limit the depth d1 of the groove 30 compared to the width w1 of the groove 30.

[0086] The grooves 30 may be formed in accordance with any suitable manufacturing method. In accordance with one method, the edges that forms the side walls of the groove are cut and then the material between the cuts is torn away. In accordance with another method, the edges that forms the side walls of the groove are cut and then the material between the cuts is compressed. In accordance with one method, the grooves are formed by milling, optionally with the edges being cut before the milling operation. Turning to Fig. 2A and 2B, a corner of the blank 1 , folded and inserted into a package 200, is illustrated. As can be seen from the figures the package 200 and the blank 1 is enlarged in the corner where the first side wall 220a and the second side wall 220b of the package 200 connects.

[0087] When the first main panel 10 is folded relative to the second main panel 11 the groove edge portion 32 of the first major surface 40 on the first panel 10 extends into the groove 30 and abuts a side wall 34 of the groove 30 formed on the second main panel 11 . This will occur in all corners where a groove 30 according to the inventive concept is provided between two panels, which preferably is as in Fig. 1 A and 1 B between all panels that are foldably connected. However, for these figures the fold between the first main panel 10 and the second main panel 11 will be used as an example. The function is equally applicable to the other panels being interconnected via such a groove 30.

[0088] The first main panel 10 is aided to keep its position in the groove 30 when the groove edge portion 32 of the first major surface 40 on the first main panel 10 is folded such that it abuts the side wall 34. This occurs due to the depth d1 of the groove 30 being greater than the width w1 of the groove 30. When the width w1 is shorter than the depth d1 , the bottom 36 of the groove 30 will provide a pulling force that keeps the first main panel 10 in position inside the groove 30. The blank 1 will therefore be aided in keeping the shape when the blank 1 is in the package 200. This prevents the blank 1 from losing its shape during transportation. In other words, the first main panel 10 is folded into the groove 30 such that a part of the first major surface 40 is located inside the groove 30 such that there is an overlap of the first main panel 10 and the second main panel 11 . This results in that the second main panel 11 meets the first main panel 10 partly up on to the first major surface 40, i.e., that a corner edge on the second main panel 11 along the groove 30 ends up in contact with the first major surface 40 at a slight distance from the corner edge on the first main panel 10 along the groove 30. Furthermore, when the depth d1 is greater than the width w1 there will be a tight fit in the connection points between the first main panel 10 and the second main panel 11 of the folded blank 1 . The first main panel 10 and the second main panel 11 will be pulled together. This typically increase the thermal insulation of the package 200 as less air may enter / leave the storage area of the package.

[0089] The blank 1 may be made of a material that is resiliently stretchable by hand such that material which is located at the bottom 36 of the respective groove 30 and which interconnects said two panels 10, 11 is stretchable, thereby aiding the groove edge portion 32 of the first main panel 10 to be positioned in the groove 30. The blank 1 may be made of a material that is resiliently compressible by hand such that the groove edge portion 38 of the first major surface 40 on the first main panel 10 is compressible, thereby aiding the groove edge portion 32 of the first main panel 10 to be positioned in the groove 30.

[0090] When the blank 1 is made of a resiliently stretchable material or a resiliently compressible material the groove edge portion 32 of the first main panel 10 is allowed to be positioned deep into the groove 30, past the nominal point of contact defined by the non-stretched geometry or non- compressible geometry. The first main panel 10 may be forced by the user to a position that would not been reached if the user was not able to momentarily reshape the blank 1 . When the groove edge portion 32 of the first main panel 10 is deeper positioned inside the groove 30 the first main panel 10 will be further secured against the second main panel 11 as a larger portion may be in abutment.

[0091] The material of the blank 1 may for example be a fibrous material comprising natural fibres having a length-weighted average fibre length from about 0.8 mm up to about 5 mm and may be provided at a concentration of at least 70 % by weight of the material, wherein the fibrous material preferably may be an air-laid material. The material of the blank 1 may have an average density of 10 to 60 kg / m3. The material of the blank 1 may in an indentation test in accordance with standard ISO 2439:2009 using a test probe diameter of 200mm and at an indentation depth of 25%, have a hardness given as a force [N] of about 7- 25N, preferably about 10-20N. With a test probe diameter of 200mm and at an indentation depth of 40%, the hardness given as a force [N] is preferably about 50-125N, more preferably about 70-100N. Preferably, at least one of the above criteria is fulfilled and more preferably both criteria are fulfilled; preferably according to the wide intervals, more preferably according to one wide interval and one narrow interval, and most preferably according to the two narrow intervals.

[0092] The resilience of the material is preferably such that there is at least 50% reflexion after release of elongations being less than 10%. This resilience of 50% reflexion is preferably at least true after being released after an elongation of less than and up to 10% for less than 5 minutes. This resilience of 50% is preferably also true after being released after an elongation of less than and up to 10% for up to 24 hours. The elongation test is e.g., performed by uniformly stretching e.g., a 10 cm by 10 cm test piece in a stretching direction extending along two of the sides and orthogonally to the other two sides, and the test piece may e.g., have a thickness of between 15- 60 mm, such as e.g., 30mm, to provide sufficient reliability and repeatability by e.g., avoiding any practical impacts due to boundary conditions which might occur if testing was to be performed on too small or thin test pieces. Long-term resilience may be determined using a compression test according to ISO standard 1856:2018. After a compression to 50% during 72h at a temperature of 23°C, the remaining compression set should preferably be less than 50, more preferably less than 30%.

[0093] Turning to Fig. 3, a full view of the folded blank 1 is illustrated. The first main panel 11 has been folded in relation the two end wall panels 20, 21 and the second main panel 11 . The second main panel 11 has also been folded in relation to the third main panel 12 and the third main panel 12 has been folded in relation to the fourth main panel. Thereby, the blank 1 has been folded into a box.

[0094] Turning to Fig. 4, a package 200 with the blank 1 folded and inserted into the package 200 is illustrated. Thereby the package 200 is provided with insulation and / or shock-absorbing properties. The package 200 comprises, a bottom wall 210 and a plurality of side walls 220a-d. The blank 1 is folded and inserted into the package 200 with the first major surface 40 of the blank 1 facing towards an interior of the package 200.

[0095] Turning to Fig. 5. a method 300 for providing a package 200 with thermal insulation and / or shock-absorbing properties is illustrated. The method comprises folding 310 a package blank into a partly closed package 200. The method 300 further comprises folding 320 the blank 1 and inserting 330 the folded blank 1 into the partly closed package 200 with the first major surface 40 of the blank 1 facing towards an interior of the package 200.

[0096] Additionally, variations to the disclosed embodiments can be understood and effected by the skilled person in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

Claims

Claims1 . A blank (1 ) to be inserted in a package (200) for providing thermal insulation and / or shock-absorbing properties to the package (200), the blank (1 ) comprising, as seen in a flat-laid state of the blank (1 ); a first set of panels (10, 11 , 12, 14) being foldably interconnected and being arranged one after the other in a longitudinal direction (L), and a second set of panels (20, 21 ) being foldably connected to one longitudinally extending edge (10a), or a respective one of two longitudinally extending edges (10a, 10b), of at least one of the panels, preferably one of the panels, of the first set of panels (10, 11 , 12, 14), wherein at least two of the panels of the first set of panels (10, 11 , 12, 14) are foldably connected along a groove (30), the groove (30) being formed in a first major surface (40) of the blank (1 ) and having a depth (d1 ) and a width (w1 ), wherein the depth (d1 ) of the groove (30) is greater than the width (w1 ) of the respective groove (30) such that, as a first panel of said at least two (10, 11 , 12, 14) of the panels of the first set of panels (10, 11 , 12, 14) is folded relative to a second panel of said at least two (10, 11 , 12, 14) of the panels of the first set of panels (10, 1 1 , 12, 14), a groove edge portion (32) of the first major surface (40) on the first panel extends into the groove (30) and abuts a side wall (34) of the groove (30) formed on the second panel.

2. The blank (1 ) according to claim 1 , wherein the blank (1 ) is made of a material that is resiliently stretchable by hand such that material which is located at a bottom (36) of the respective groove (30) and which interconnects said at least two (10, 1 1 , 12, 14) of the panels of the first set of panels (10, 1 1 , 12, 14) is stretchable, thereby aiding the groove edge portion (32) of the first panel to be positioned in the groove (30).

3. The blank (1 ) according to claim 1 or claim 2, wherein the blank (1 ) is made of a material that is resiliently compressible by hand such that thegroove edge portion (32) of the first major surface (40) on the first panel is compressible, thereby aiding the groove edge portion (32) of the first panel to be positioned in the groove (30).

4. The blank (1 ) according to any one of the preceding claims, wherein the groove (30) has a rectangular cross-sectional shape.

5. The blank (1 ) according to any one of the preceding claims, wherein all of the panels (10, 11 , 12, 14) of the first set of panels (10, 11 , 12, 14) are foldably connected to neighbouring panels (10, 11 , 12, 14) of the first set of panels (10, 1 1 , 12, 14) along a respective groove (30), wherein, preferably, each groove (30) has a depth (d1 ) being greater than a width (w1 ) thereof.

6. The blank (1 ) according to any one of the preceding claims, wherein the panel or those panels (20, 21 ) of the second set of panels (20, 21 ) that are directly connected to a panel (10, 11 , 12, 14) of the first set of panels (10, 11 , 12, 14) is / are foldably connected thereto along a respective groove (30), wherein, preferably, each groove (30) has a depth (d1 ) being greater than a width (w1 ) thereof.

7. The blank (1 ) according to any one of the preceding claims, wherein all of the panels (20, 21 ) of the second set of panels (20, 21 ) is / are foldably connected to a panel (10, 1 1 , 12, 14) of the first set of panels (10, 11 , 12, 14) or to a panel (20, 21 ) of the second set of panels (20, 21 ) along a respective groove (30), wherein, preferably, each groove (30) has a depth (d1 ) being greater than a width (w1 ) thereof.

8. The blank (1 ) according to any one of the preceding claims, wherein the blank (1 ) has a material thickness of 15-60mm.

9. The blank (1) according to any one of the preceding claims, wherein the depth (d1) of the groove (30) is from 50% to 80% of the material thickness, and preferably from 60% to 80% of the material thickness.

10. The blank (1 ) according to any one of the preceding claims, wherein the depth (d1) of the groove (30) is from 105% to 140% of the width (w1 ), and preferably from 105% to 125% of the width (w1 ).11 . The blank (1 ) according to any one of the preceding claims, wherein the material of the blank (1 ) is a fibrous material comprising natural fibres having a length-weighted average fibre length from about 0.8 mm up to about 5 mm and being provided at a concentration of at least 70 % by weight of the material, wherein the fibrous material preferably is an air-laid material.

12. The blank (1 ) according to any one of the preceding claims, wherein the material of the blank (1 ) has an average density of 10 to 60 kg / m3.

13. A package (200) having thermal insulation and / or shock-absorbing properties, the package (200) comprising, a bottom wall (210), a plurality of side walls (220a-d), and a blank (1 ) according to any one of claims 1 -12, wherein the blank (1) is folded and inserted into the package (200) with the first major surface (40) of the blank (1 ) facing towards an interior of the package (200).

14. A method (300) for providing a package (200) with thermal insulation and / or shock-absorbing properties, the method comprising folding (310) a package blank into a partly closed package (200), folding (320) a blank (1 ) according to any one of claims 1 -12,inserting (330) the folded blank (1 ) into the partly closed package (200) with the first major surface (40) of the blank (1 ) facing towards an interior of the package (200).

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